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Halogen Free PV Cable PV1-F 450/750V - China Suppliers & Factory Compliant with 2 Pfg 1169/08.2007 Standards
Construction
(1) Conductor
Number of conductors: 1
The conductor is class 5, according to EN 60228.
The single wires are tinned.
Preferred diameters: 2.5, 4, 6, 10, 16 mm²
(2) Insulation
The insulation is a suitable halogen free material applied around the conductor.
The insulation is extruded and consist of one or several adjacent adherent layers. It is solid and homogeneous, it is possible to remove it without damage to the insulation itself, to the conductor and to the tin coating.
The insulation is smooth, consistently applied and largely circular.
(3) Sheath
The core is covered by a sheath.
The sheath around the core is of a suitable halogen free material.
The sheath is extruded and shall consist of one or several adjacent adherent layers. The sheath is smooth and consistently applied.
Current Carrying Capacity of PV-Cables
| Rated diameter | Kind of installation | ||
|---|---|---|---|
| Single cable free in air | Single cable on surfaces | To cables adjacent on surfaces | |
| mm² | A | A | A |
| 1.5 | 30 | 29 | 24 |
| 2.5 | 41 | 39 | 33 |
| 4 | 55 | 52 | 44 |
| 6 | 70 | 67 | 57 |
| 10 | 98 | 93 | 79 |
| 16 | 132 | 125 | 107 |
| 25 | 176 | 167 | 142 |
| 35 | 218 | 207 | 176 |
Conversion Factor for Deviating Temperatures
| Ambient temperature (°C) | Conversion factor |
|---|---|
| Up to 60 | 1.00 |
| 70 | 0.91 |
| 80 | 0.82 |
| 90 | 0.71 |
| 100 | 0.58 |
| 110 | 0.41 |
Tests for Halogen Free PV-Cable
| 1 | 2 | 3 | 4 | 5 | ||
|---|---|---|---|---|---|---|
| Ref. No. | Test | Requirements | Category of test | Test method described in | ||
| standard | clause | |||||
| 1 | Electrical tests | |||||
| 1.1 | Resistance of conductors | T.S | EN 50395 | 5 | ||
| 1.2 | Voltage test on completed cable with AC or DC | T.S | EN 50395 | 6 | ||
| – AC-test-voltage | kV | 6.5 | ||||
| – DC- test-voltage | kV | 15 | ||||
| Length of sample | m | 20 | ||||
| Duration of test | min | 5 | ||||
| Temperature of the water | °C | 20±5 | ||||
| 1.3 | Absence of faults at complete cable | R | EN 50395 | 10 | ||
| – AC-test-voltage | kV | 10 | ||||
| 1.4 | Surface resistance of sheath | T | EN 50395 | 11 | ||
| – Minimum value | Ω | 109 | ||||
| 1.5 | Insulation at complete cable | T | EN 50395 | 8 | ||
| Length of sample | m | 5 | ||||
| Duration of test | h | 2 | ||||
| Temperature of the water | °C | 20±5 | ||||
| – Minimum value at 20 °C | Ω·cm | 1014 | ||||
| – Minimum value at 90 °C | Ω·cm | 1011 | ||||
| 1.6 | Long term resistance of insulation to d.c. | T | Annex D | |||
| 2 | Constructional and dimensional tests | |||||
| 2.1 | Checking of compliance with constructional provisions | T.S | Inspection and manual tests | |||
| 2.2 | Measurement of thickness of insulation | T.S | EN 50396 | 4.1 | ||
| 2.3 | Measurement of thickness of sheath | T.S | EN 50396 | 4.2 | ||
| 2.4 | Measurement of overall dimensions | |||||
| 2.4.1 | – Mean value | T.S | EN 50396 | 4.4 | ||
| 2.4.2 | – Ovality | % | ≤15 | T.S | EN 50396 | 4.4 |
| 3 | Pressure test at high temperature at complete cable | T | EN 60811-3-1 | |||
| 3.1 | Test conditions: | |||||
| – temperature | °C | 140±3 | ||||
| – duration of heating under load | min | 240 | ||||
| – Coefficient k | 0.6 | |||||
| 3.2 | Results to be obtained: | |||||
| – depth of penetration, max. | % | 50 | ||||
| – Voltage test 10 min after exculpation and cooling | Table 4, 1.2 | |||||
| 4 | Damp heat test | T | EN 60068-2-78 | |||
| 4.1 | Test conditions: | |||||
| – temperature | °C | 90 | ||||
| – duration | h | 1000 | ||||
| – relative humidity | % | 85 | ||||
| 4.2 | Results to be obtained: | |||||
| – variation of tensile strength | max.% | -30 | ||||
| – variation of elongation at break | max.% | -30 | ||||
| 5 | Resistance against acid and alkaline solution | T | EN 60811-2-1 | 10 | ||
| 5.1 | Chemical stress | |||||
| acid: | N-Oxal-acid | |||||
| alkaline solution: N-sodium hydroxide solution | ||||||
| temperature | °C | 23 | ||||
| duration | h | 168 | ||||
| 5.2 | Tensile strength: | |||||
| variation, max. | % | ±30 | ||||
| 5.3 | Elongation at break, min. | % | 100 | |||
| 6 | Test of influence | T | Annex A | |||
| 7 | Cold impact test at –40 °C | T | Annex E | |||
| 8 | Cold bending test | T | EN 60811-1-4 | 8.2 | ||
| Diameter of cable < 12.5 mm | ||||||
| 8.1 | Test conditions: | |||||
| – temperature | °C | –40 ± 2 | ||||
| – duration of conditioning | h | 16 | EN 60811-1-4 | 8.2.3 | ||
| 8.2 | Results to be obtained | Absence of cracks | ||||
| 9 | Cold elongation test | Table 3 | ||||
| Diameter of cable ≥ 12,5 mm | ||||||
| 10 | Ozone resistance at complete cable | T | ||||
| 10.1 | Method B | EN 50396 | 8.1.3 | |||
| – temperature | °C | 40 ± 2 | ||||
| – relative humidity | % | 55 ± 5 | ||||
| – duration | h | 72 | ||||
| – Ozone concentration (by volume) | % | (200 ± 50) × 10–6 | ||||
| 10.2 | Results to be obtained | Absence of cracks. | ||||
| 11 | Weathering/UV-resistance | T | HD 605/A1 | 2.4.20 | ||
| 11.1 | Conditions: | |||||
| – duration | h | 720 | ||||
| – temperature (Black-Standard-temperature) | °C | 63 | ||||
| – relative humidity | % | 65 | ||||
| – min. power at wavelength 300 nm to 400 nm | W/m² | 60 ± 2 | ||||
| – duration spraying/drying | min | 18/102 | ||||
| Results to be obtained | Absence of cracks. | |||||
| 12 | Dynamic penetration test | T | Annex F | |||
| 13 | Notch propagation | T | Annex G | |||
| 14 | Shrinkage test at complete cable | T | EN 60811-1-3 | 11((sheath)) | ||
| 14.1 | Conditions: | |||||
| – temperature | °C | 120 | ||||
| – duration | h | 1 | ||||
| – Distance L of sample | mm | 300 | ||||
| 14.2 | Results to be obtained: | |||||
| – Maximum shrinkage. | % | 2 | ||||
| 15 | Test under fire conditions | |||||
| 15.1 | Test for vertical flame propagation at complete cable | T.S | EN 60332-1-2 | |||
| 15.2 | Assessment of halogen | T.S | ||||
| 15.2.1 | Absence of halogen | Annex B | ||||
| 15.2.2 | Determination of halogens – | Annex C | ||||
Requirements for Halogen Free Insulation and Sheath Compounds
| 1 | 2 | 3 | 4 | 5 | 6 | 7 |
|---|---|---|---|---|---|---|
| Ref. No. | Test | Unit | Test method described in | Type of compound | ||
| standard | clause | insulation | sheath | |||
| 1 | Mechanical characteristics | |||||
| 1.1 | Properties before ageing | EN 60811-1-1 | 9.2 | |||
| 1.1.1 | Values to be obtained for the tensile strength: | |||||
| – median, min. | N/mm² | 6.5 | 8.0 | |||
| 1.1.2 | Values to be obtained for the elongation at break: | |||||
| – median, min. | % | 125 | 125 | |||
| 1.2 | Properties after ageing in oven | EN 60811-1-2 | 8.1 | |||
| 1.2.1 | Ageing conditions: | |||||
| – temperature | °C | 150 ± 2 | 150 ± 2 | |||
| – duration of treatment | h | 7 × 24 | 7 × 24 | |||
| 1.2.2 | Values to be obtained for the tensile strength:c | |||||
| – median, min. | N/mm² | - | - | |||
| – variation, max. | % | –30a | –30a | |||
| 1.2.3 | Values to be obtained for the elongation at break:c | |||||
| – median, min. | % | - | - | |||
| – variation, max. | % | –30a | –30a | |||
| 1.3 | Hot set testd | EN 60811-2-1 | 9 | |||
| 1.3.1 | Conditions | |||||
| – Temperature | °C | 200± 3 | 200± 3 | |||
| – Time under load | min | 15 | 15 | |||
| – mechanical stress | N/cm² | 20 | 20 | |||
| 1.3.2 | Values to be obtained | |||||
| – elongation under load, max. | % | 100 | 100 | |||
| – permanent elongation after cooling, max. | % | 25 | 25 | |||
| 1.4 | Thermal endurance properties | EN 60216-2 | ||||
| 1.4.1 | Conditions | |||||
| Either test of elongation at break or bending test shall be performed. | ||||||
| – Temperature index | 120 | 120 | ||||
| – elongation at breakc | % | 50 | 50 | |||
| – bending test | EN 50305 | 7.2 | 2 D | 2 D | ||
| 1.5 | Cold elongation test | EN 60811-1-4 | 8.4 | |||
| 1.5.1 | Conditions: | |||||
| – temperature | °C | –40 ± 2 | –40 ± 2 | |||
| – duration | h | EN 60811-1-4 | 8.4.4 und 8.4.5 | b | b | |
| 1.5.2 | Values to be obtained: | |||||
| – elongation at break, min. | % | 30 | 30 | |||
| a No positive value for variation fixed. | ||||||
| b See test method in column 4 and 5. | ||||||
| c This test is performed at test samples of insulation and sheath compound. | ||||||
| d This test is performed only at cross-linked insulation and sheath compound | ||||||
Advantages
(1) Consistent Product Quality
Our company utilizes high-quality raw materials and advanced manufacturing processes to ensure that the products meet customers' specifications and performance requirements. Supported by a comprehensive inspection system, we rigorously monitor quality from four key stages: raw material inspection, in-process inspection, semi-finished product inspection, and finished product inspection. Throughout production, we strictly implement data collection protocols and retain product samples, ensuring full traceability for every item.
(2) Industry-Leading Delivery Speed
We maintain ample inventory across all product categories, enabling us to promptly fulfill urgent customer demands. Additionally, our strategic stock of semi-finished products, combined with a highly flexible production management approach, allows us to efficiently address diverse and time-sensitive customer requirements.
(3) Tailored Customization Services
For customized product requests, we have established a sophisticated and streamlined workflow. Each custom project is supported by a dedicated one-on-one service team, comprising experts from R&d, sales, production, after-sales, and other relevant departments. This structure ensures professional and efficient solutions tailored to the customer's specific needs.
Frequently Asked Questions (FAQ)
What are the main construction materials used in these PV-cables?
The cables are constructed with a tinned class 5 conductor (compliant with EN 60228), surrounded by extruded halogen-free insulation and covered by a halogen-free sheath. Both insulation and sheath are designed to be smooth and consistently applied.
How does ambient temperature affect the current capacity of the cables?
As the ambient temperature increases, a conversion factor must be applied to adjust the current carrying capacity. The factor is 1.00 for temperatures up to 60°C, and decreases progressively (e.g., 0.71 at 90°C and 0.41 at 110°C) to prevent overheating.
What tests are performed to verify the low-temperature performance of the cables?
The cables undergo a cold impact test at -40°C (Annex E), a cold bending test (EN 60811-1-4 clause 8.2) for cables under 12.5 mm, and a cold elongation test (EN 60811-1-4 clause 8.4) to ensure they do not crack or fail in freezing conditions.
What are the requirements for the insulation and sheath compounds before and after ageing?
Before ageing, the minimum tensile strength must be 6.5 N/mm² for insulation and 8.0 N/mm² for the sheath, with a minimum elongation of 125%. After oven ageing at 150°C for 7 days, the maximum permitted variation in both tensile strength and elongation is ±30%.
How do you ensure consistent quality and traceability for your PV-cables?
We implement a comprehensive quality control system across four stages: raw material inspection, in-process inspection, semi-finished product inspection, and finished product inspection. All production data is logged, and product samples are kept to ensure full traceability.